Sterile pack carton



Sept 1970 H. R. JAESCHKE 3,526,353

STERILE PACK CARTON I Filed April 9, 1968 5 Sheets-Sheet :3

.J 10 F/ 6314 w} 4 ,5 4 w ATTORNEY United States Patent Oflice 3,526,353Patented Sept. 1, 1970 3,526,353 STERILE PACK CARTON Harold R. Jaeschke,Milwaukee, Wis., assignor to Hoerner Waldorf Corporation, St. Paul,Minn., a corporation of Delaware Filed Apr. 9, 1968, Ser. No. 719,978Int. Cl. B65d 5/54 US. Cl. 229-51 Claims ABSTRACT OF THE DISCLOSURE Theinvention discloses a tubular sleeve having end closures includingclosure flanges and sealing flanges. Theclosure flanges on the top andbottom panels are folded into end abutting relation, and the sealingflanges are sealed in face contact. The closure flanges on the sidewalls are diagonally creased so that the sealing flanges may be foldedflat to provide double thickness struts which project from the cartonends and extend beyond that carton side walls. Opening means areprovided which are so arranged that the sterile contents may be removedwithout becoming contaminated.

This invention relates to an improvement in sterile packages and dealsparticularly with a paperboard carton containing sterile dressings andthe like.

For many years sterile dressings have been contained in pouches made offoil or similar material which must be individually opened as required.Packages of this type must normally be sterilized before use in order toprevent contamination by contact of the dressing with the outer surfacesof the pouches, or else must be opened with extreme care to avoid thepossibility of contamination due to contact with the outer surface ofthe pouch.

It has long been considered desirable from a standpoint of economy andfor other reasons to package such dressings in paperboard cartons. Oneof the biggest difliculties is the ditficulty of sealing such cartons sothat the contents remain sterile during shipment and handling. Anotherdifficulty lies in producing a package of this type from which thesterile contents may be removed without contact between the contents andthe exterior surface of the package. The outside surfaces of thepackages are normally not sterile, and it is necessary for the nurse ordoctor to contact the outer surfaces of the packages in order to openthem so that the hands or gloves become contaminated by contact with thecartons. It is the purpose of the present invention to provide apaperboard carton which may be used to contain sterile dressings or thelike and from which i the contents may be removed without contaminatingthe contents by contact with the outer surfaces of the cartons.Alternatively, it is an object of the present invention to provide apackage which may be opened up to expose the contents without actuallycoming in contact with the contents, and from which the contents may beremoved with out contaminatiing the gloves or hands or the operator.

A feature of the present invention resides in the provision of a tubularpaperboard carton having end closures including end flanges connected tothe top, bottom, and side walls of the tube, and having sealing flangehingedly connected to the end closure flanges. The end closed flangesare preferably approximately one-half the height of the side walls so asto meet in abutting relation. The sealing flanges of both the side andend walls are folded flat and sealed together under heat and pressure.The end flanges secured to the side walls are diagonally folded alongfold lines converging from the corners of the top and bottom panels tothe hinge line connecting the side wall end flange to the side wallsealing flanges. As a result, suficient sealing pressure may be appliedto the sealing flanges to hermetically seal the contents.

A further feature of the present invention resides in the provision of aglue flap which is hinged to one of the side walls and is secured inface contact to the adjacent edge of a top or bottom wall. This glueflap is provided with an end flange and sealing flange which are securedto the end flange and sealing flange of the wall which the glue flapoverlaps. The inner opposed surfaces of the sealing flaps are preferablyprovided with heat activatable adhesive which functions when the sealingflaps are clamped together to form an air tight seal between the sealingflaps. In order to eliminate any air channel adjoining the edge of theglue flap where an air passage would normally be formed at thetransition from the area of three thicknesses to the area of twothicknesses, the sealing flaps are embossed inwardly, causing theadhesive to flow against the edge of the top Wall sealing flange in thisarea and to prevent the air passage from being formed.

A further feature of the present invention resides in the provision of acarton of the type described which, in its preferred form, includes ahandle flange or tab providing an extension of the glue flap andoverlying the central portion of the panel to which the glue flap issecured. Weakened lines of separation extend from opposite ends of thishandle flap across the glue flap, across the side wall to which the glueis hinged, across the panel opposite that to which the glue flap isadhered, and across the second side wall. By grasping the handle flapand tearing the paperboard across three walls of the carton, the entirecentral portion of the contents is exposed without the contents evercoming into contact with the hands or the external surface of thecarton. The contents may then be removed using sterile gloves or hands.

The opening of the carton in the manner described provides anarrangement which comprises a pair of opposed hollow rectangular endcaps connected by a flat connecting panel. By providing score linesacross this panel on opposite sides of the open area, the end may engageand the end caps hinged in such a manner that the contents may bedropped upon a sterile tray or other support if it is desired. Thisoperation is simplified by the fact that the sealing flanges formoppositely directed struts which may be grasped to simplify the handlingoperation.

A further feature of the present invention resides in the provision of adevice of the type described in which the weakened lines of separationdefining the carton opening are formed by cut lines extending partiallythrough the paperboard from opposite sides thereof. The cut lines in theinner surface of the cartons are closer together than the cut lines inthe outer surface thereof. While weakened lines of this type are wellknown in the art, they provide a particular advantage in the presentconstruction, When the detachable portion of the carton has been opened,the opening is encircled by a lip having on its inner side the sterileinner surface of the package and having as its outer surface anintermediate layer of the paperboard which was previously between theinner and the outer surfaces. As a result, in the removal of thecontents from the carton, the contents are protected by the sterileperipheral lip and may be readily removed without contact with theexterior surface of the carton itself.

A further feature of the present invention lies in the provision of acarton, the body of which is held out of contact with the walls of anenclosing container. The paperboard struts project from two opposed endsof the container, and the sides of these struts project beyond thecarton side walls, holding the rectangular carton body spaced from anyof the walls of an enclosing container.

These and other objects and novel features of the present invention willbe more clearly and fully set forth in the following claims.

In the drawings forming a part of the specification:

FIG. 1 is a perspective view of the sealed carton as it appears inshipment and storage.

FIG. 2 is a perspective view of the inverted carton after the packagehas been opened.

FIG. 3 is a diagrammatic side elevation review showing the manner inwhich the contents of the package may be dropped from the package onto asterile tray or other support without contact with the contents.

FIG. 4 is an enlarged sectional view through the embossed area of thepackage, the position of the section being indicated by the line 4-4 ofFIG. 1.

FIG. 5 is an enlarged sectional view through the panel of the package,the position of the section being indicated by the line 55 of FIG. 1.

FIG. 6 is a diagrammatic view of the blank from which the carton isformed.

FIG. 7 is a perspective view of a sealed container of modified form.

FIG. 8 is a greatly enlarged sectional view through the paperboard, theposition of the section being indicated by the line 88 of FIG. 7.

FIG. 9 is a vertical section view through the sealed container, theposition of the section being indicated by the line 99 of FIG. 7.

FIG. 10 is a diagrammatic view of the blank from which the carton ofFIG. 7 is produced.

FIG. 11 is a perspective view of another modified form of the cartonconstruction in sealed condition.

FIG. 12 is a perspective view of the carton of FIG. 1 in open position.

FIG. 13 is an elevational view of the carton shown in FIG. 11.

FIG. 14 is a vertical sectional View through the carton shown in FIG.11, the position of the section being indicated by the line 1414 of FIG.13.

FIG. 15 is a diagrammatic view showing the blank from which the cartonof FIGS. 11 through 14 is made.

The carton A is formed of the blank illustrated in FIG. 6 of thedrawings. As indicated, the blank includes a top wall 110, a first sidewall 11, a bottom wall 12, and a second side wall 13, the walls orpanels being generally rectangular and being foldably connected alongparallel fold lines 14, 1'5, and :16. The glue flap 17 is hingedlyconnected to the side wall panel 13 along a fold line 19'. Obviously,the terms top wall and the bottom wall are merely for the purpose oforientation in description, as the carton may be inverted or otherwisesupported.

End closure flanges 20, 21, 22, and 23 are foldably connected to thepanels 10, :11, 12, and 13 along parallel fold lines 24. End closureflanges are also provided on opposite ends of the glue flap 17 alongextensions of the fold lines 25. The length of the end closure flanges20 and 22 in a direction normal to the fold lines 24 is substantiallyequal to one-half the width of the side walls #11 and 13, or one-halfthe distance between the fold lines 14 and 115-. As a result, when theclosure flanges 20 and 22 are folded at right angles to the panels 10and 12 to which they are hinged, these flanges extend in substantiallyend abutting relation. Sealing flanges 26, 27, 29, and are hingedlyconnected to the end closure flanges 20, 21, 22, and 23 along commonlines of fold 31. A sealing flange 32 is also secured to each glue flapend flange 25 along the continuation of a fold line 30.

Each side wall end flange 21 is divided in three triangular sections bya pair of diagonally extending converging fold lines 33 and 34 whichconverge from the intersections of the fold lines 14 and 24, and thefold lines 15 and 3-4 respectively. The diagonal fold lines 33 and 34come to an apex at a corresponding fold line 3 1. A fold line 35 extendsfrom the apex of the triangle formed by the converging fold lines 33 and34, the fold lines 35 extending across the sealing flanges 27 parallelto, and

midway between, the fold lines :14 and 15. The side wall and closureflaps 23 are similarly divided into three triangular areas by a pair ofconverging fold lines '37 and 39 which converge from the junctures ofthe fold lines 16 and 24 and the fold lines 19 and 24 respectively. Thefold lines 37 and 39 come to an apex of the fold lines 37 and 39 acrossthe sealing flanges 30, the fold lines 40 being midway between, andparallel to, the fold lines 16 and :19.

A handle flap 41 is hingedly connected to the glue flap 17 along a foldline 32 which is parallel to the fold line 19 hingedly connecting theglue flap to the side wall 13. A pair of parallel weakened lines ofseparation 43 extend from opposite ends of the handle flap 41 across theglue flap 17, the side wall 13, the bottom panel 12 and the side wall11. The weakened lines of separation are spaced inwardly from the foldlines 24 defining the ends of the carton panels, and the handle flap isof corresponding length. Each weakened line of separation includes a cutscore line 44 which extends into the outer surface of the paperboard andextends partially through the thickness of the paperboard to terminate ashort of the inner surface thereof, as is indicated in FIG. 5 of thedrawings. A pair of parallel side by side cut score lines 45 extend intothe paperboard on the inner surface thereof, the cut score lines 45 alsoextending at least half way through the paperboard but terminating shortof the outer surface 46 of the board. As a result, the cut score lines45 which extend into the inner surface 47 are between or inwardly of thecut score lines 44 and the outer surface 46 of the board. Score lines 49form extentions of the weakened lines of separation 43 and extend inparallel relation across the top of panel 10.

The carton A is set up by adhering the glue flap 17 together with itsclosure flap 25 and sealing flap 32 in face contact with the outersurface of the top panel 10, the end closure flap 20 and the sealingflap 26 at each end thereof. In other words, the blank is securedtogether throughout its entire width. After the surgical dressings orother such means have been inserted into the carton, the various sealingflaps are folded into face contact, the end closure flanges 20 and 22extending toward one another in substantially right angular relation tothe panels to which they are hinged, and the triangular areas outwardlyof the diagonal fold lines 33, 34, 37, and 39 form extensions of theclosure flanges 20 and 22, as indicated in the drawings. The sealingflange structure is folded at its ends along the fold lines 35 and 40,and the sealing flanges are sealed together under heat and pressure. Thecontacting surfaces of the sealing flanges are preferably provided withheat activatable adhesive and will adhere together to form a pair ofstiff struts at each end of the carton which are arranged on a planesubstantially parallel to the planes of the top and bottom panels 10 and12.

Due to the fact that considerable pressure may be applied to the sealingflaps, the flaps may be hermetically sealed together. The only areawhere much likelihood of air leakage may occur is along the hinged edgeof the glue flap sealing flange 32 where it overlies the edge of 49 ofthe sealing flange 26 of the panel 10. It has been found that byembossing small areas of the paperboard together at the point, theadhesive connecting the sealing flanges will be forced against the edges49 of the panel 10 to fill any small channel which might otherwise occurin this area. The numeral 50 indicates adhesive which has been forcedagainst the edge 40 of the panel 10 by the inward embossing 51 ofopposite sides of the sealing flanges 26 and 30. This embossing has beenfound to eifectively seal any air channel so that the contents of thecarbon are hermetically sealed.

Now when it is desired to open the carton, the handle flap 41 is graspedand pulled back disconnecting the adhesive bond between the centralportion of the glue flap 17 and the top panel 10. A continued outwardpulling on the handle flap 41 will cause the carton to tear across theside wall 13. The carton may be inverted and the tearing continuedacross the panel 12 and the side wall 11. The container then appears asindicated in FIG. 2 of the drawings.

The dressings B may be removed from the package A when in the positionillustrated in FIG. 2 due to the fact that only the portions of thecarton engaged by the dressing during removal thereof are the inwardlyprojecting lips which are uncontaminated. If it is desired to completelyremove the dressings, they may be placed on a sterile tray such as C byflexing the rectangular flaps upwardly in manner illustrated in FIG. 3by engaging the struts formed by the sealed sealing flanges, and bendingthe panel along the fold lines 49, the contents dropping under the trayas the carton is flexed.

FIGS. 7 through 10 of the drawings show a modified form of constructionD which differs from the carton A only in the type of tear strip whichhas been employed to open the carton. In order to simplify thedescription the various panels and flanges have been given the sameidentifying numerals as were used in the carton A. The only differencebetween the general shape of the blank D and the blank A is the factthat the handle tab 41 is eliminated in the blank D.

In order to open the carton D, a tear strip is pro vided whichpreferably extends entirely about the blank. A pair of parallel cutscore lines 55 extend across the blank D in spaced relation, these cutscore lines being shown nearer one end fold line 24 of the panels thanthe other. As indicated in FIG. 8 of the drawings, these out score lines55 extend into the outer surface of the paperboard and preferably extendslightly more than onehalf the thickness of the paperboard, butterminates short of the inner surface of the sheet. A second pair of cutscore lines 56 are arranged in the inner surface of the paperboard inside by side relation to the cut score lines 55, but are somewhat closerthan the cut score lines 55 and are inwardly thereof. As is well knownin the art, when the portion of this tear strip between the cut scorelines 56 is grasped and pulled outwardly, the paperboard splitsintermediate the outer surface 57 of the sheet and the inner surface 59thereof, presenting an inwardly extending lip along each edge of thespace produced by removal of the tear strip.

It will further be noted that the lips such as 59 formed by splittingthe paperboard along the broken lines 60 are sterile in view of the factthat no part of this lip has become contaminated due to contact withother objects. This is of importance as the sterile lip acts to preventthe contents of the package from being contaminated upon removal fromthe carton.

An arcuate or U-shaped out line 61 is provided in the outer surface ofthe paperboard, and an arcuate or U-shaped out score 62 of somewhatlarger radius but having a common center with the cut score line 62 asprovided in the inner surface 59 of the board. This arrangement ofarcuate cut score lines is shown as being in the side wall panel 13closely adjacent to the fold line 16 connecting the side wall 10 to thepanel 12. The arcuate cut score line defines a tab which may be pushedinwardly to provide a means of grasping an end of the tear strippermitting the tear strip to be removed completely out of the package.It is recognized that some difliculty some times is experienced indisconnecting the double thickness areas of the carton where the glueflap overlies the panel 10. However, by this time the carton has beenopened across three of the four walls, the carton may be flexed or bentin order to assist the separation.

In this arrangement, the two end portions of the carton may becompletely separated to permit the dressings or other contents of thecarton to be dropped onto a sterile tray such as C without having thecarton contents come into contact with the hands or with any portion ofthe outer surface of the carton.

FIGS. 11 through 15 of the drawings show another modified form of cartonwhich is indicated in general by the letter B. For the purpose ofsimplifying the description the various panels forming the blank havebeen given the same identifying numerals as the corresponding panels ofthe blanks A and D. The various wall panels, end closure flanges,sealing flanges, and the like are identical to those of the blank B.

The carton E is normally used where it is desired to retain the sterilecontents of the carton in the carton until they are removed for use.Actually, the carton B may be reclosed if desired without contaminatingthe contents. As indicated in FIG. 15 a pair of cut score lines 64coincide with the fold lines 15 and 16 in the outer surface of thepaperboard from the fold line 24 which is uppermost in FIG. 15 for adistance of perhaps one-third to one-half the length of panel 12.Converging cut score lines 65 also in the outer surface of thepaperboard extend from the lower ends of the cut score lines 64 toterminate in spaced relation at the lower score line 24. An arcuate orU-shaped cut score line 66 is provided in the inner surface of thepaperboard connecting the ends of the cut score lines 65, the cut scoreline 66 being in the end flange 22.

A pair of cut score lines 67 are provided in the inner surface of thepaperboard extending in closely spaced relation to each cut score line64 and being of substantially equal length thereto. Converging cut scorelines 69 in the inner surface of the paperboard extend in parallelclosely spaced relation to the cut score lines 65 and are locatedinwardly thereof. The cut score lines 69 at their lower ends arepreferably parallel as indicated at 70 to extend directly beneath thelocation of the ends of the cut score lines 65. A semi-circular cut orU-shaped score line 71 which is concentric with the cut score line 66 isprovided in the outer surface of the paperboard terminating at the lowerfold line 64. The arcuate cut score line 71 is of smaller radius thanthe inner cut score line 66.

When the carton has been filled and sealed in the manner which has beendescribed in conjunction with the carton A, the contents will remainhermetically sealed during shipment and storage. However, when it isdesired to open the carton, inward pressure is applied to thesemicircular area 72 within the cut score line 71. This inward pressurecauses the paperboard to split between the inner and outer surfacesthereof, providing a tab, the periphery of which is sterile. Once thepad has been pushed in, the area adjoining the tab may be grasped andpulled upwardly, the panel 12 opening in the manner illustrated in FIG.12 of the drawings. It will be noted that the area encircling theopening is encircled by the sterile inwardly projecting lip and theinner sterile surface of the opened flap so that the dressings or othercontents may be removed through the opening by a person using sterilegloves or hand without forming contact between the contents and theexterior contaminated surface of the carton.

In accordance with the patent statutes, I have described the principlesof construction and operation of my improvement in tape holding rolls;while I have endeavored to set forth the best embodiment thereof, Idesire to have it understood that obvious changes may be made withoutdeparture from the spirit of my invention.

I claim:

1. A package for sterile dressings and the like including:

top, bottom, and side walls of paperboard connected in tubular relation,

end wall flanges hinged to the ends of said top and bottom and side walland being of a length substantially one-half the width of said sidewalls, said end wall flanges of said top and bottom walls meeting in endabutting relation,

sealing flanges hingedly secured to said end wall flanges and sealed inface contact,

the end wall flanges of said side walls being diagonally creased alongconverging fold lines extending from the corners of the top and bottomwalls to the center of the fold lines connecting said side wall end wallflanges to said sealing flanges,

a fold line extending across said sealing flanges from the apex of eachpair of converging flanges parallel to the connected edges of said top,bottom, and side walls along which said sealing flanges are folded intofact contact,

said sealing flanges projecting from the ends of said walls on a planesubstantially parallel to the planes of said top and bottom walls andthe portions of said side wall end wall sealing flanges on oppositesides of said last named fold lines extending laterally beyond said sidewalls to provide double thickness protective struts projecting beyondsaid top and bottom walls and laterally of said side walls.

2. The structure of claim 1 and including a glue flap on one side walloverlapping one of said top and bottom Walls and including glue flapextensions secured in face contact with the end wall flange and sealingflange hinged to said one wall.

3. The structure of claim 2 and including a potential opening in atleast one of said walls, said opening being defined by double cut linescomprising side by side out lines extending into the paperboard from theouter and inner surfaces thereof, the cut lines in the inner surfacebeing inwardly toward one another from the adjoining cut lines in theouter surface.

4. The structure of claim 2 and including a tear strip extending acrossat least three of said walls at right angles to the fold linesconnecting said walls in tubular relation, said tear strip, when removedpermitting the opening up of the carton to permit removal of the cartoncontents by grasping the struts at opposite ends of the carton.

5. The structure of claim 1 and including a glue flap secured to one ofsaid side walls and secured in overlapping relation with one of said topand bottom panels and outwardly on the surface thereof, a handle flapterminating short of the ends of said one panel, and weakened lines ofseparation extending across said glue flap at the ends of said handleflap, across the side wall to which said glue flap is secured, acrossthe other of said top and bottom walls, and across the other of saidside walls.

6. The structure of claim 5 and including score lines extending acrosssaid one wall from the ends of said weakened lines in said other sidewall to the ends of said handle flap.

7. The structure of claim 5 and in which said weakened lines ofseparation comprise side by side cut lines extending partially throughthe paperboard from opposite surfaces thereof, the cut lines in theinner surface being closer together than the cut lines in the outersurface whereby when the carton is torn along its weakened lines, theinner edges of the opening thus formed remains sterile.

8. The structure of claim 2 and in which the contacting surfaces of saidsealing flanges are coated with a heat activatable adhesive sealed byheat and pressure.

9. The structure of claim 2 and in which the contacting surfaces of saidsealing flanges are coated with heat activatable adhesive, and in whichthe portions of said sealing flanges adjoining the edge of said glueflap are embossed toward one another to force adhesive along the edge ofsaid glue flap to provide a hermetic seal.

10. A carton opener for use in paperboard cartons having a pair ofconnected Wall panels having the opener including:

a pair of weakened lines of separation extending into one of said panelsfrom the edge thereof foldably connecting said panels,

each said weakened line including side by side cut score lines extendinginto the paperboard from opposite surfaces thereof, the cut score linesin the inner surface being closer together and between, the cut scorelines in the outer surface,

a generally U-shaped cut score line in the inner surface of the otherpanel having its ends substantially coinciding with the ends of said outscore lines in the outer surface of said one panel at said edge thereof,and a U-shaped cut score line of smaller size in the outer surface ofsaid other panel within the confines of said U-shaped cut score in theinner surface and spaced therefrom.

References Cited UNITED STATES PATENTS 2,214,172 9/1940 Moore. 3,019,9442/1962 Nelson et al. 3,056,665 10/ 1962 Linda et al. 3,167,238 1/1965Smith. 3,259,303 7/1966 Repko. 3,301,391 1/1967 Guyer. 3,391,852 7/ 1968Waldrop. 3,399,820 9/1968 Foster et al. 3,402,875 9/1968 Palmer.

FOREIGN PATENTS 151,773 12/1937 Austria.

D. T. MOORHEAD, Primary Examiner US. Cl. X.R. 20656

